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ABB HT575027 manual available for free PDF download: Operation Manual
ABB HT575027 Operation Manual (142 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 18.93 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
4
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Introduction
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Deflagration on Gas Engines
15
Warning Plates on the Turbocharger
16
Turbocharger Rating Plate
17
Periodic Check of the Pressure Vessels
18
Lifting of Loads
19
Prerequisites for Operation and Maintenance
20
Hazards During Operation and Maintenance
21
Safe Operation
23
Safe Maintenance
25
Product Description
31
Essential Information
33
Introduction
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Fig. 1: Layout and Function of the Turbocharger
34
Layout and Function of the Turbocharger
34
Fig. 2: Compressor Wheel Cooling
35
Fig. 3: Warning Plate Locations
36
Warning Plates on the Turbocharger
36
Fig. 4: Locations of the Rating Plates
37
Locations of the Rating Plates
37
Fig. 5: Suspension of Complete Turbocharger Unit
38
Removing and Installing
38
Table 2: Weights of Turbochargers A130-M
38
Turbocharger Weight and Transportation
38
Fig. 6: Removing the Turbocharger
39
Removing the Turbocharger
39
Fig. 7: Loosening the Clamping Nut
41
Fig. 8: Turbocharger Centre of Gravity
42
Fig. 9: Inserting Gaskets into the Bracket
43
Installing the Turbocharger
43
Fig. 10: Inserting the Threaded Rods
44
Fig. 11: Requirements for Threaded Rods
44
Table 3: Requirements for Threaded Rods
44
Fig. 12: Placing the Turbocharger on the Bracket
45
Table 4: Tightening Torques for Standard Nuts
46
Fig. 13: Preparing the Clamping Nut for the Tightening Procedure
47
Fig. 14: Tightening Pressure Screws
48
Table 5: Pressure Screw Tightening Torques
48
Fig. 15: Connecting the Compressor Cooling Air Intake
49
Fig. 16: Attaching the Support
49
Commissioning
50
Oil Supply
50
Fig. 17: Oil Orifice
51
Inspection Procedures
52
Commissioning after Taking out of Operation
54
Monitoring Operation
55
Oil Pressure, Oil Temperature
55
Table 6: Lubricating Oil Pressure, Oil Inlet
55
Table 7: Lubricating Oil Temperature at the Inlet
56
Table 8: Lubricating Oil Temperature at the Outlet
56
Exhaust Gas Temperature before Turbine
57
Fig. 18: Layout and Overview of Speed Measurement System
58
Turbocharger Speed
58
Fig. 19: Replacing the Speed Sensor
60
Table 9: Tightening Torque (86505)
60
Fig. 20: Noise Insulation, Bellows
61
Noise Emission
61
Operation and Service
61
Service Work
63
Fig. 21: Replacing the Protective Grid
65
Expected Replacement Intervals
67
Table 10: Expected Replacement Intervals
67
Stopping the Engine
69
Foreword to Maintenance
70
Periodic Maintenance Work
70
Table 11: Maintenance Table
70
Cleaning the Compressor During Operation
71
Fig. 22: Carrying out Wet Cleaning of Compressor
74
Table 12: Parameters for Wet Cleaning of Compressor
74
Cleaning the Turbine During Operation
75
Table 13: Turbine Wet Cleaning, Recommended Operating State
77
Fig. 23: Carrying out Wet Cleaning of Turbines
78
Table 14: Wet Cleaning of Turbines, Parameters
78
Cleaning Components Mechanically
79
Fig. 24: Cleaning the Filter Silencer
80
Fig. 25: Compressor-End, Non-Rotating Parts
82
Fig. 26: Turbine End, Non-Rotating Parts
83
Fig. 27: Soaking the Turbine End
86
Table 15: Value Table for Soaking
86
Eliminating Malfunctions
89
Malfunctions When Starting
89
Table 16: Malfunctions When Starting - Delayed Start-Up
89
Table 17: Malfunctions When Starting - Vibrations
89
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
89
Malfunctions During Operation
90
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
90
Table 20: Malfunctions During Operation - Speed Reduces
90
Table 21: Malfunctions During Operation - Speed Increases
90
Table 22: Malfunctions During Operation - Exhaust Gas Temperature too High
91
Table 23: Malfunctions During Operation - Charge Air Pressure too Low
91
Table 24: Malfunctions During Operation - Charge Air Pressure too High
92
Table 25: Malfunctions During Operation - Engine Performance Losses
92
Table 26: Malfunction - Turbocharger Pumping
93
Table 27: Malfunction - Sporadic Surge Blows
93
Turbocharger Is Surging
93
Malfunctions When Stopping
94
Table 28: Malfunctions When Stopping - Runout Noises
94
Table 29: Malfunctions When Stopping - Runout Time too Short
94
Speed Measurement System
95
Table 30: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
95
Table 31: Malfunction of the Speed Measurement System - Measured Speed too High
95
Table 32: Malfunction of the Speed Measurement System - Measured Speed too Low
95
Dismantling and Fitting
96
Introduction
96
Table 33: Swivel Lifting Eyes
98
Table 34: Ring Nuts to be Used
99
Fig. 28: Weights of Assemblies
100
Table 35: Weights of Assemblies
100
Weights of Individual Parts
100
Fig. 29: Removing Air Inlets
101
Removing Air Inlets
101
Fig. 30: Removing the Insulation
102
Removing the Gas Outlet Casing
102
Fig. 31: Removing the Gas Outlet Casing
103
Removing the Gas Outlet Flange
104
Fig. 32: Dismantling the Gas Outlet Flange
105
Table 36: 3 Press-Off Screws
105
Fig. 33: Removing the Gas Outlet Flange
106
Table 37: 6 Press-Off Screws
106
Fig. 34: Removing the Compressor Casing
107
Removing the Compressor Casing
107
Fig. 35: Dismantling the Wall Insert
108
Fig. 36: Press off the Casing
109
Pressing off the Casing
109
Fig. 37: Removing Insulation Sheets
110
Fig. 38: Oil Orifice
110
Removing the Cartridge Group
110
Fig. 39: Removing Cartridge Group 1
111
Fig. 40: Removing Cartridge Group 2
111
Fig. 41: Removing the Nozzle Ring
112
Removing the Nozzle Ring
112
Fig. 42: Installing the Cartridge Group on the Service Support
113
Installing the Cartridge Group on the Service Support
113
Axial Clearance a and Radial Clearance B
114
Fig. 43: Measuring Clearance a and B
114
Table 38: Permissible Clearances a and B
114
Fig. 44: Nozzle Ring Compression PD
115
Nozzle Ring Compression PD
115
Table 39: Permitted Nozzle Ring Compression PD
115
Fig. 45: Installing the Nozzle Ring
116
Installing Nozzle Ring
116
Fig. 46: Lifting the Cartridge Group and Rotating It
117
Installing the Cartridge Group
117
Fig. 47: Installing the Cartridge Group
118
Table 40: Tightening Torque (51007)
118
Fig. 48: Turbine Casing Insulation / Burst Protection
119
Installing the Compressor Casing
120
Table 41: Tightening Torque (79041)
120
Fig. 49: Installing the Compressor Casing
121
Table 42: Tightening Torque (72011)
121
Fig. 50: Measuring Clearances N and R
122
Radial Clearances N and R
122
Table 43: Permissible Clearances N and R
122
Fig. 51: Installing the Air Inlets
123
Installing Air Inlets
123
Table 44: Tightening Torque (72020)
123
Fig. 52: Installing the Gas Outlet Flange
124
Installing the Gas Outlet Flange
124
Fig. 53: Fitting the Insulation
125
Fig. 54: Installing the Gas Outlet Casing
126
Installing the Gas Outlet Casing
126
Table 45: Tightening Torque (51009)
126
Fig. 55: Fitting the Insulation
127
Fig. 56: Tightening Torques
128
Table 46: Tightening Torques
128
Table of Tightening Torques
128
Fig. 57: Tightening Torques for Insulation
129
Table 47: Tightening Torques for Insulation
129
Possible Emergency Repairs
130
Taking out of Operation at Short Notice
130
Installing a Replacement Cartridge Group
131
Installing a Replacement Turbocharger
131
Fig. 58: Fitting the Cover Plate
132
Fitting the Cover Plate
132
Cover Plate Drawing
133
Fig. 59: Cover Plate Drawing
133
Table 48: Cover Plate Dimensions [MM]
133
Mothballing the Turbocharger
134
Taking the Engine out of Operation for up to 12 Months
134
Taking the Engine out of Operation for more than 12 Months
135
Disposing of Turbocharger Components
136
Ordering Spare Parts
137
Required Customer Spare Part Set (97070)
137
Spare Parts
137
Table 49: Customer Spare Part Set 97070
137
Fig. 60: Overview of Part Numbers
138
View of Turbocharger with Part Numbers
138
Table 50: Spare Parts List
139
Figures
140
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